Double-Sided Fabric Embedded With Curved Linear Material
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current flat bed knitting machines are limited in embedding continuous linear materials longer than 1 inch due to inclined angles, resulting in unsatisfactory fabric production, and existing methods cannot form double-sided fabrics with curved patterns or incorporate conductive yarns effectively.
Innovation Solution
A flat bed knitting machine with a loop presser bed and staggered needles allows for the embedding of continuous linear materials to form curved patterns in double-sided fabrics, enabling the use of conductive yarns and maintaining fabric thickness and piling effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If yarn stitching operations using a knitting needle are used to embed continuous linear material, then the embedding process can be performed, but the continuous linear material cannot be reliably stitched when its length exceeds 1 inch due to inclined angle issues
Solution Approach 1:
The patent introduces a yarn guide as an intermediary component between the yarn feeder and the knitting needle. This yarn guide redirects the continuous linear material at an appropriate angle, eliminating the inclined angle problem that occurs when feeding material directly to the knitting needle. The yarn guide acts as a mediator that enables reliable stitching of continuous linear material regardless of its length.
Solution Approach 2:
The patent replaces the traditional direct mechanical feeding system with a guided routing system. Instead of relying on the knitting needle to directly engage and stitch the continuous linear material at varying angles, the system uses a yarn guide to pre-position and redirect the material, substituting the direct mechanical interaction with an indirect guided approach that ensures consistent stitching.
2Shape
If a flat bed knitting machine with front and back needle beds is used, then single-sided or double-sided fabric can be manufactured, but existing methods cannot form curved patterns with embedded continuous linear material
Solution Approach 1:
The patent applies curvature by strategically positioning knitting needles at different heights and angles on the front and back needle beds. This creates a three-dimensional curved path for the embedded continuous linear material, transforming flat linear embedding into curved spatial patterns. The curved arrangement of needles enables the formation of decorative curved designs within the fabric structure.
Solution Approach 2:
The patent transitions from two-dimensional flat pattern embedding to three-dimensional curved pattern formation by utilizing the vertical and spatial dimensions provided by the front and back needle beds. The continuous linear material is embedded along curved trajectories that extend through multiple dimensions, adding spatial complexity and design versatility to the fabric patterns.
3Strength
If existing embedding methods are used, then simple linear patterns can be formed, but thicker and denser fabrics with more pattern changes and better shape sustainability cannot be achieved
Solution Approach 1:
The patent merges the functions of both front and back needle beds to simultaneously create dense fabric structure and complex embedded patterns. By coordinating the operation of needles on both beds, the system embeds continuous linear material in a way that reinforces the fabric structure while creating multiple pattern variations, achieving both strength and design complexity.
Solution Approach 2:
The patent creates a composite fabric structure by embedding continuous linear material (such as conductive yarn or decorative thread) within the base fabric matrix formed by the front and back needle beds. This composite construction combines the structural properties of the base fabric with the functional or aesthetic properties of the embedded material, resulting in thicker, denser fabric with enhanced shape sustainability and pattern complexity.
Data Source
AI summary
A double-sided fabric embedded with a continuous linear material and formed as a curved form. The double-sided fabric is knit by a flat bed knitting machine including a front needle bed including front knitting needles, a back needle bed including back knitting needles and a loop presser bed including right-directed and left-directed knitting pressing pieces. The double-sided fabric includes a continuous linear material pressed by the right-directed and/or left-directed knitting pressing pieces and embedded into the double-sided fabric to form loop groups. Each loop group includes loops stitched and formed by one front knitting needle and two back knitting needles at two sides of the front knitting needle in a knitting process and in next knitting process. At least two of the loops groups are located in different knitting processes to cause a level drop in the continuous linear material to form at least one curved portion.